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techtalk:evo:oil04b [2019/07/24 04:06] hippysmack [EVO: Oiling & Lubrication - Sub-04A] |
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| - | ====== EVO: Oiling & Lubrication - Sub-04B ====== | ||
| - | ====== 04 Style Oil Cap Repair ====== | ||
| - | Article by JohnK of the XLFORUM ((http://xlforum.net/forums/showthread.php?t=1566307)) \\ | ||
| - | If you've noticed your oil cap mysteriously popping up, it could be a broken internal sleeve. \\ | ||
| - | One of the first symptoms is that the cap will not stay flush, but will protrude maybe an eighth of an inch above the tank surface. \\ | ||
| - | Eventually it will not click down in place at all. \\ | ||
| - | Take a close look just under the cap, where the plunger enters the body. \\ | ||
| - | The black sleeve protruding above the grey body (in the right side arrow in the 1st pic below) may indicate a broken sleeve. \\ | ||
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| - | |The sleeve should be flush around the perimeter as \\ shown by the left side arrow. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|To disassemble, find the two side square tabs and \\ push each one in, and the mechanism will pop out \\ under spring pressure. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))| This is what you will have, notice the ratchet spring \\ on the side, note how it fits for re-assembly later. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))| | ||
| - | |{{:techtalk:evo:oil:oil_cap_repair_1_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_2_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_3_by_johnk.jpg?direct&300|}}| | ||
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| - | Now take a look at the bottom of the 'sleeve'. \\ | ||
| - | It should be one piece. \\ | ||
| - | The two halves are held together by two very thin sections of plastic on the bottom (as in the circled areas below). \\ | ||
| - | In this case, the sleeve was broken into two pieces. \\ | ||
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| - | The locking tabs are both on one half of the sleeve, the other side is free to slide inside the body. \\ | ||
| - | As long as the sleeve is joined together in one piece that's fine. \\ | ||
| - | But the bottom thin section is prone to cracking. \\ | ||
| - | (one side is locked and the other moves up and down ever so slightly each time the cap is popped) \\ | ||
| - | Once this fails, the 'loose' side will protrude up as seen in the first pic above. \\ | ||
| - | The side without the locking tabs is also the side with the ratchet spring. \\ | ||
| - | (which adds additional up and down drag every time the mechanism is worked, accelerating the failure) \\ | ||
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| - | |The thin connecting material was broken out. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|Here are all the components, minus the broken out \\ pieces. The sleeve is now in two halves. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|Note the locking tabs on one half of the sleeve and \\ none on the other. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))| | ||
| - | |{{:techtalk:evo:oil:oil_cap_repair_4_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_5_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_6_by_johnk.jpg?direct&300|}}| | ||
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| - | The solution was to re-assemble the mechanism and install a set-screw to hold the loose side in place. \\ | ||
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| - | The entire operation shouldn't take more than an hour, if you take your time. \\ | ||
| - | The only items required are a small screwdriver to push in the locking tabs, a set screw, an appropriate drill bit and drill. \\ | ||
| - | You can find a small flat head screw, countersink the hole and drive the screw head flush for a better-than original look and function. \\ | ||
| - | {{:techtalk:evo:oil:oil_cap_repair_1_by_samjmm.jpg?direct&300|}} ((photo by samjmm of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307&page=4)) \\ | ||
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| - | Below, a brass screw from an electrical lug was used to screw through the grey plastic body and into the black inner sleeve. \\ | ||
| - | It was short enough not to interfere with the moving plunger while long enough to screw through the grey plastic body to the sleeve. \\ | ||
| - | Find a way to hold the sleeve down flush with the outer body and drill a hole slightly smaller than the screw thread. \\ | ||
| - | Drill it right through both the body and sleeve. \\ | ||
| - | It can be done with the plunger installed but it would be better to leave it out. \\ | ||
| - | Drive the screw into the plastic, it will cut its own thread (that's why you drill a smaller pre-drill size hole). \\ | ||
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| - | |Finished product. ((photo by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|Here's what it looks like from the inside. The spot for this particle drilled hole put the screw partially in the slot, \\ which would have nullified the fix. A smarter choice would have been into one of the lugs as indicated below. ((photos by JohnK of the XLFORUM http://xlforum.net/forums/showthread.php?t=1566307))|| | ||
| - | |{{:techtalk:evo:oil:oil_cap_repair_7_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_8_by_johnk.jpg?direct&300|}}|{{:techtalk:evo:oil:oil_cap_repair_9_by_johnk.jpg?direct&300|}}| | ||
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